Cap assembly for pile shell



April 16, 1.968 J. J. DOUGHERTY 3,377,808

CAP ASSEMBLY FOR PILE SHELL Filed Dc. 25, 195e v 2 sheets-sheet 1 INVENTOR, JOHN J DOUGHERrY BY x A Colw- .5. H/

TTORA/ E April 16, 1968 J. J. DOUGHERTY CAP ASSEMBLY FOR -PILE SHELL 2 Sheets-Sheet 2 Filed Dec. 23, 1966 INVENTOR. Jo/-l/v J.l DOL/GHERTY BY H77.' TORNEY United States Patent O 3,377,808 CAP ASSEMBLY FOR PILE SHELL .lohn Joseph Dougherty, Cedar Grove, NJ. (262 Rutherford Blvd., Clifton, NJ. 07014) Filed Dec. 23, 1966, Ser. No. 604,433 Claims. (Cl. 61-53) This invention relates to new and useful improvements and refinements in cap assemblies for shells of piles, and more particularly to a cap assembly for a shell, Said cap assembly having a concavo-convexo or J1rusto-conical shaped body of spring steel with corrugations or teeth running radially between the inner narrow end and the outer wider end of the body of the assembly with an upright band around the periphery of the outer wider end of the body.

Piles under piers are usually formed of timber and deteriorate, become damaged and are subject to fire hazards and accordingly must be repaired from time to time which is very difficult because of the lack of space within which to operate. In such repairing operations, the top of the pile is often cut off leaving a space between the top of the cut timber and the floor of the pier, making it necessary to building the pile structure up until it reaches and supports the floor of the pier.

It is an important object of the present invention to provide a perforated cap assembly for capping one `end of a shell whereby the shell and cap assembly as a unit may be slid over the top of a timber pile at the pier for receiving concrete whereby the pile structure may be ybuilt up to the floor of the pier or the like.

Another important object of the invention is to provide a new method of repairing and/or constructing piles under piers and the like.

Yet another important object of the present invention is to provide a length of concrete pile around and above the top of a timber pile, and the method of making such length of concrete pile.

Still another object of the invention is to provide a cap assembly for such a length of concrete pile whereby the length of concrete pile may be constructed at the site.

Yet another object of the invention is to provide a perforated cap assembly having a frusto-conical shaped body with corrugations therealong for attachment to the end of a shell or tube, the cap assembly and shell adapted to be slid over the top end of a timber pile to receive concrete, which assembly upon pouring of the concrete will anchor and keep anchored the inner tip ends of its corrugations in the outer surface of the timber pile under the most adverse conditions by utilizing the elasticity inherent in the spring body, the eXtra ordinarily strong spring `force of such a frusto-conical Vbody being capable of equalizing every pressure brought to bear thereagainst.

Another object is to provide a cap assembly of this kind capable of absorbing an increased pressure without breaking.

A specific object of the invention is to provide a cap assembly having a frusto-conical body with corrugations running radially on the outer surface thereof, which assembly has a combined locking and shakeproof effect.

Other objects of the invention are to provide a perforated cap assembly for capping the bottom end of a shell and reinforcing the shell, which can be manufactured readily and economically.

For further comprehension of the objects and advantages of the invention, reference will be had to the following description thereof taken in connection with the accompanying drawings wherein:

FIG. 1 is a bottom perspective view of a cap assembly for a concrete pile section made in accordance with the present invention.

FIG. 2 is a top plan view as seen from the line 2-2 of FIG. 1.

FIG. 3 is a cross-sectional View taken on the plane of the line 3-3 of FIG. 2.

FIG. 4 is a plan view of the blank from which the cap assembly of FIG. 1 is made, parts being broken away.

FIG. 5 is a bottom perspective view showing the cap assembly applied to the bottom end of a helical shell or tube.

FIG. 6 is a vertical sectional view of a concrete pile section taken through the center thereof with the cap assembly applied thereto and showing the pile section applied to the top of a timber pile under a pier.,`

FIG. 7 is a vertical sectional view of a fragment of a modified form of concrete pile section shown applied to the top of a timber pile, the concrete being omitted.

FIG. 8 is a top plan view as seen from the line 8 8 of FIG. 7.

In FIG. l, an embodiment of the cap assembly o-f the present invention is shown and designated 10. The cap assembly 10 is formed from the blank 12 of spring steel shown in flattened condition in FIG. 4, consisting of an elongated rectangular shaped body 14 formed with a fold line 16 therealong adjacent one long edge, its bottom edge, defining a band portion 18, the band portion having a short extension 20 at one end. The remainder of the :body of the blank is grooved and bent transversely forming corrugations 22, the material of the blank being formed with V-shaped notches 24 along its other long edge. The notches define inverted V-shaped tip ends 26 on the inner ends of the corrugations and define inner pointed ends 28 and oblique edges 30 of the notches between the outer tip ends 26 and the pointed ends 28.

When the blank 12 is looped into annular or ring-like formation and its outermost corrugations 22, as seen in FIG. 4, welded to each other as indicated at 32, and the band portion 18 turned inwardly along the fold line 16, over the bases of the corrugations 22, with its extension 20 -overlapping the adjacent end of the band portion, as indicated at 34, the blank forms the frusto-conical body 36, with continuous band 38, as seen in FIG. 1, with a gutter 40 at the juncture of the bases of the corrugations 22 and band 38. An opening 42 is formed in the inner or top end of the body as viewed in FIG. l, that is at the top of the frustrum. n

4By virtue of the above described construction of the cap assembly, there has been provided a very simple construction which can be attached to a shell or helical tubing in a minimum of time and effort. The attachment of the -cap assembly to the shell or tubing is very strong and through the provision of adaptability to meet manufacturing tolerances, there a has been provided a cap assembly which can be used under field operation by relatively unskilled personnel.

The use of the cap assembly 10 in its attachment to the end of a helical shell or tube 46 is simple. In this operation, the cap assembly 10 is slipped over one end of the shell, the bottom end as viewed in FIG. 5, until it overlaps the -bottom helical convolutions 48 of the shell, and until the bottom end edge of the shell seats in the gutter 40. The band 38 is then spot welded to the bottom convolutions of the shell as indicated' at 50 whereby the frusto-conical body of the cap assembly is centered interiorly of the shell 46. The shell 46 and attached cap assembly 10, as a unit, are slid over the top end S2 of a timber pile 54 until the bottom edge of said cap assembly rests upon a pair of supports 56 secured in place by fastening elements 58. The supports 56 are secured to the pile at a predetermined distance from the top edge 52 of the pile to allow the top edge of the shell 46 to become level with the bottom of the pier floor F or other structure to be supported by the concrete capped pile. The distance of the supports 56 from the top edge 52 of the pile and the length of the shell 46 will vary in accordance with the requirements of the particular job. When the shell and cap assembly are thus positioned on the timber pile 54, concrete 6@ is poured over and around the top end 52 of the timber pile 54, down into the gutter 40 and over the corrugated frusto-conical body 36 until the concerete reaches the top of the shell 46 and is levelled off. During the operation of pouring the concrete, the unit including the shell 46 and cap assembly 10 remain in fixed position. The inner pointed ends 26 of the corrugations and the oblique edges 30 function as inclined planes or wedges which redirect loosening forces on the timber pile surface to a tightening direction due to the corrugated formations 22 and the resiliency of the spring steel from which the cap assembly is formed. Furthermore, such pointed ends 26 and the -oblique edges 30 function as an interlocking force between the body of the cap assembly and the outer surface of the timber pile 54 which counteracts any loosening generated.

It will be understood that the dimensions of the blank are dependent upon the diameter of the pile upon which it is to be assembled.

In FIGS. 7 and 8, the cap assembly 10 is shown attached to a sectional shell or tube 46 composed of two semi-cylindrical sections 64 and 66 with juxtaposed flanges S and 7 t), respectively, along the long edges thereof. The flanges are secured together by bolt and nut assemblies 72 in spaced relation therealong. The cap assembly 10 is welded to the bottom end of the shell as indicated at 74.

While I have illustrated and described the preferred embodiment of my invention, it is to be understood that I do not limit myself to the precise construction herein shown and described and any modifications may be made therein without departing from the principle of the invention as defined in the appended claims.

I claim:

1. As an article of manufacture, a cap assembly for a pile shell comprising a frusto-conical body of spring steel having an opening in the narrow end thereof and having a band around the wide end thereof, said band extending inwardly along the body in spaced relation thereto, said body being corrugated, the corrugations extending from the opening to the band, the edge of the body forming the opening being notched between the ends of the corrugations.

2. As an article of manufacture, a cap assembly for a pile shell as defined in claim 1 wherein the notches are V-shaped defining inverted V-shaped ends on the adjacent ends of the corrugations, the inverted ends adapted to flex for interlocking with a timber pile and the like.

3. As an article of manufacture, a cap assembly for a pile shell as defined in claim 1 wherein a gutter is formed at the juncture between the band and the adjacent ends of the corrugations for seating the end of a pile shell.

4. As an article of manufacture, a cap assembly for a pile shell as defined in claim 2 wherein a gutter is formed at the juncture between the band and the adjacent ends of the corrugations for seating the end of a pile shell, the band being welded to the end of the shell.

5. A composite pile including a timber pile section, and a concrete pile section around the top of the timber pile section, said concrete pile section including a shell, a perforated cap assembly attached to the bottom end of the shell and concrete in the shell over and around the top end of the timber pile and over and around the cap assembly, said cap assembly having a frusto-conical body with an opening in the narrow end thereof receiving the timber pile, and a band around the wide end of the body extending inwardly along the body in spaced angular relation thereof for attachment to the adjacent end of the shell, the edge wall of the narrow opening being notched forming inner pointed ends adapted to interlock with the top end of the timber pile.

References Cited UNITED STATES PATENTS 910,453 1/1909 Black et al. 61-54 1,514,065 11/1924 Leary 285-138 X 1,947,413 2/1934 Hay 61-54 X 3,338,058 8/1767 Young 61-63 X FOREIGN PATENTS 1,045,296 10/ 1966 Great Britain.

JACOB SHAIIRO, Primary Examiner. 

1. AS AN ARTICLE OF MANUFACTURE, A CAP ASSEMBLY FOR A PILE SHELL COMPRISING A FRUSTO-CONICAL BODY OF SPRING STEEL HAVING AN OPENING IN THE NARROW END THEREOF AND HAVING A BAND AROUND THE WIDE END THEREOF, SAID BAND EXTENDING INWARDLY ALONG THE BODY IN SPACED RELATION THERETO, SAID BODY BEING CORRUGATED, THE CORRUGATIONS EXTENDING FROM THE OPENING TO THE BAND, THE EDGE OF THE BODY FORMING THE OPENING BEING NOTCHED BETWEEN THE ENDS OF THE CORRUGATIONS. 